4.

5M C/KU BAND FULL MOTION

ANTENNA USER MANUAL

All-Seeing Technology Co., Ltd

F29, Building 57th, No. 36 North Park Rd,
Xincheng District, Xi’an, China 710032
Phone: +86 29-88860263
Email: [email protected]
http://www.allseeingtech.com
 4.5M VSAT ANTENNA USER MANUAL

4.5M C/ KU BAND 360°FULL MOTION ANTENNA

TABLE OF CONTENTS

SECTION TITLE

Ⅰ GENERAL INFORMATION

1.0 INTRODUCTION

1.1 UNPACKING AND INSPECTION

1.2 MECHANICAL INSTALLATION TOOLS

1.3 SITE SELECTION

1.4 FOUNDATION REQUIREMENTS

1.4.1 CONCRETE MOUNT

1.4.2 NON-PENETRATING MOUNT

II MAIN REFLECTOR ASSEMBLY

III SUB-REFLECTOR ASSEMBLY

IV KINGPOST ASSEMBLY

V CONNECTION OF KING POST WITH THE HUB

VI LIMIT SWITCHES AND RESOLVERS ASSEMBLY

VII 2 PORTS FEED SYSTEM ASSEMBLY

Ⅷ SUB-REFLECTOR ADJUSTMENT

Ⅸ AERONAUTICAL LAMP ASSEMBLY

LIGHTNING KIT ASSEMBLY

Ⅹ

Ⅺ ANTENNA ASSEMBLY PROCESS WITHOUT CRANE

Ⅻ ANTENNA SYSTEM OPERATION AND MAINTENANCE

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 4.5M VSAT ANTENNA USER MANUAL

4.5M FULL MOTION ANTENNA

SECTION I GENERAL INFORMATION

1.0 INTRODUCTION
This manual describes the assembly and installation of AST’s 4.5M Rx/Tx antenna system. The AST
4.5M is a rugged, reliable antenna system that will operate at C/Ku/Ka-band frequencies with high
efficiency and at the same time withstand the effects of the environment.

These instructions are listed by sections that cover all areas of assembly and installation. Addition
sections are included in the manual to provide information on antenna alignment to the satellite and
maintenance.

450EC/EK type 4.5-metre rotatable satellite communication antenna is an earth station antenna
designed and produced by AST. It is a dual reflector modified ring focus antenna with good
performance.
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4.5m antenna is composed of main reflector, sub- reflector, feed, mount, Az/El driving units, Az/El
sensor, Az/El positioned and so on.

The main reflector is a parabolic that is made by spinning antirust alloy aluminum, and the reflector
back structure is made of high intensity aluminum alloy to enable the antenna to survive after strong
wind and the main reflector to maintain the precision.

Main reflector and sub-reflector are sprayed with high voltage static by using epoxy polyester, the
surface of steel components is all treated by spraying hot zinc or dipping hot zinc to increase the ability
of antisepsis.

The feeding system of the antenna is made up with a conic ripple horn and an Rx/Tx duplexer.

The conic ripple horn is abortively designed and processed, can bring perfect spherical wave with
symmetrical circle. It’s sidelobe with low power level ensures the antenna have good electric
performance as high efficiency, low sidelobe, low noise temperature and low cross polarization power
level etc.

The antenna mount is situated in the way of elevation and azimuth. The turn of antenna is controlled by
ACU (ADU) and two 380-watt AC motor in door.

1.1 UNPACKING AND INSPECTION

The antenna containers should be unpacked and inspected at the earliest date to ensure that all
material has been received and is in good condition. A complete packing list for each major component
is supplied.
Any damage to materials while in transit should be immediately directed to the freight carrier. He will
instruct you on the matters regarding any freight damage claims.
Any questions regarding missing or damaged materials that is not due to freight carrier should be
directed to AST Customer Service Department at:

All-Seeing Technology Co., Ltd

Email: [email protected]
Tel: +86 29 88860263

Installation Notice
1. Divide the antenna by marks (# number) on the packing if the number of antennas is many on
installation site. (Such as #2 is the second set）.

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2. Do not open all packages while installing antenna, just open the needed one according to the
packing list. Put back the parts which are not to be used to prevent missing.
3. Tighten the bolts diagonally as there are several bolts to be fixed.
4. During installation, installer should wear soft sole footwear, to avoid damaging surface of
antenna when standing on antenna.

1.2 MECHANICAL INSTALLATION TOOLS

TOOLS SIZE QUANTITY REMARK

14x17mm 3

17x19mm 3
Open-ended spanner Stainless
19x22mm 2 steel

13mm 2

Adjustable wrench 36x300mm 2 Stainless

steel
For foundation bolts

Hammer Standard 1 iron

Screw driver Standard ( “-“ & “+”) 2

Ladder Height: 3m 1

1.3 SITE SELECTION

In order to achieve maximum performance of your antenna system, it is important to select the correct
location for the antenna. The following guidelines should be observed when selecting a site for the
installation.
1. The line of site to the satellite should be clear of any obstructions, such as trees or buildings.
2. The site should be relatively flat and level for ease of installation and access to the antenna.
3. The site should be checked for underground obstruction, such as buried cables or pipes.
4. All local building codes should be adhered to (such as grounding, foundation requirements, zoning
rules, setbacks, etc)

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4.5M Full Motion Antenna Drawing

Figure 1

1.4FOUNDATION REQUIREMENTS
1.4.1 CONCRETE MOUNT
Foundation Part list

FOUNDATION PARTS LIST

ITEM DESCRIPTION QTY REMARK

1 Foundation templet 1
2 Anchor bolt 8
3 Nut 16
4 Flat washer 8
5 Lock washer 8

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1.3.1.2 Drawings of foundation

All rebar intersects

with steel wire

unit: mm
Figure 2

4.5M Full Motion Antenna Subjected To Wind Condition Table

Wind speed 56 m/s (90°) 32 m/s 28.4 m/s Taking the Max
Max pressure Kg 2042 3222 (10°) 2645 (10°) 3222
Max lift Kg 351 1007 (160°) 875 (160°) 1007
Max horizontal force Kg 1560 1008 (150°) 864 (150°) 1560
Max wind moment Kg.m 2751 3614 (160°) 3010 (160°) 3614

Technical requirements
1. The bottom of the pit is not less than 1kg/cm2 of pressure soil, paving stones and compaction.
2. When the steel bar and anchor bolts contradiction is allowed to change the interval.
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 4.5M VSAT ANTENNA USER MANUAL
3. Pour with 300 concretes, then stir with vibrator to leave no gaps.
4. The vertical error of the anchor bolt is not more than 0.5mm, and the horizontal error is not more
than 1.5mm per meter.
5. The curing period is 21 days to reach 210Kg/cm2 pressure.

Working requirements
1. Self weight of 4.5m antenna is 1100kgs
2. Please refer to foundation drawing to make foundation
Northern hemisphere Y in the drawing point to north
Southern hemisphere Y in the drawing point to south
3. The standard grade of concrete should not be less than 200#, soil bearing capacity should be no
less than 10T/cm2
4. The size of foundation concrete is 2500mm × 2500mm,and the depth is no less than
400mm,foundation rebar is made up of 150mm×150mm lattice, the lattice is welded by Ф12
rebar , lattice have three layers.
5. The level difference of foundation installation should less than 1.5mm
6. The material of anchor bolt is steel whose standard grade is 45#, the material of others parts is A3
# steel

Install foundation template

For ensuring the location of anchor bolt exact after pouring concrete, please use foundation template.

Making foundation
1. Install temple’s and anchor rod, one Nut and one flat washer onto the anchor rod, then insert the
anchor rod into one of the holes in the template and install another nut and flat washer, verticality
between anchor rod and ground ≤1mm,repeat this procedure for the remaining anchor rods.
2. Tie rebar lattice, and weld anchor rod and the rebar lattice by manual electric arc (exposed part of
anchor rod should be protected.), pour concrete until keeping the top surface of concrete and
bottom surface of top layer template in the line.
3. During pouring concrete, the concrete should be vibrating and made firm by ramming, allow
concrete 20 days set time before installation of antenna for bearing capacity can be
210kg/cm2.After pouring concrete, exposed part of anchor rod should be oiled by grease.
Once the concrete is dry remove the top foundation template, then use nuts, flat washers and spring
washers to install the pedestal on to the anchor bolt.

1.4.2 NON-PENETRATING MOUNT (OPTION)

Name Spec QTY

Main frame 2
Bolt M20x50 8
Flat washer Φ20 16
Spring washer Φ20 8
Nut M20 8
Bolt M24×80 8

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 4.5M VSAT ANTENNA USER MANUAL
Nut M24 8
Flat washer Φ24 16
Spring washer Φ24 8

4.5M NON-PENETRATING MOUNT INSTRUCTIONS

4.5M Non penetrating mount is made from steel structure, sprayed the sealed paint on the structure,
which convenient to move. The mount base is designed in the state of 12-grade wind (33m/s) and
antenna locked without work. The NMP should be located on building roof, and the cross of spandrel
girder.

1. Please select a site with hardened concrete flat roof of the building and the level height difference
is no more than 1mm to prepare install the non-penetrating mount.
2. 4.5M non-penetrating mount is composed of two pieces of steel structures; put them flat and using
8 pieces of hex bolt and nut from intermediate to fix them together tightly.
3. Install the antenna pedestal on the non-penetration mount with M20x60 hex bolt and nut as shown
point C and fixed them tightly.
4. Install the Az stand on the non-penetrating mount with M20x50 bolt and nut, fixed them tightly.
5. Put some heavy block on the non-penetrating mount (such as sand bag, cement bag, etc) about
4500kgs.

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unit: mm
Figure 3

SECTION II MAIN REFLECTOR ASSEMBLY

The main reflector is an important part of the antenna. Its installing precision has a strong effect on the
electronic performance of the antenna. The installing procedure should comply with the following.

● Reference with Packing List to take out of back structure, brace and hub.12 x back structures have

been marked on number “N-01”,”N-02”,……,”N-12”. The marks correspond with hub.

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 4.5M VSAT ANTENNA USER MANUAL

Bolt M8×25
Spring washer Ø8
Flat washer Ø8

Taper pin

Back structure Bolt M10×20

Spring washer Ø10
Flat washer Ø10

Figure 4

Please refer to the Figure 4 to fix back structure to the upper connect point of hub and use bolt
boltM10x20, spring washer Ø8, flat washer Ø8 and nut Ø8 to fix back structure on the lower
connect point of hub, then use bolt M8x25, spring washer Ø8 and flat washer and nut Ø8 to
connect brace with back structure as Figure 5, don’t tighten bolts.
● Main reflector assembly: Antenna reflector panels for 4.5m antenna are interchangeable, so there

are not numbers in the panels, user can assemble the panels discretionarily. Please carefully take

out of the reflector panels and freely install each panel small land by using bolt M8x30, spring

washerØ8, flat washer Ø8 and nut Ø8 to connect with hub. The middle part and the end should be

fixed by bolt M8x25, spring washer Ø8, flat washer Ø8 and nut Ø8 to back structure. The main

reflector is fixed counter-clockwise.

Brace

Figure 5

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 4.5M VSAT ANTENNA USER MANUAL

Middle
connecting point

Outer connecting
point

Inner
connecting
point

Figure 6

After finish 12 panels, adjust intervals between contiguous panels, until all areas of panels are uniform,

tighten all bolts (include all bolts to be used to connector hub, back structure and reflector), then

inspect and ensure installation precision.

SECTION III SUB-REFLECTOR ASSEMBLY

1.Preparation work

A). Take out four sub-reflectors support struts, brackets, and square steel from the wooden case 7-4.

B). Take out the sub-reflector from the wooden case 7-5

2. sub- reflector installation

A). Use the bolt of M8x25, flat washer and spring washer connect one end of sub-reflector strut with

square steel, use the M8 bolt fix sub-reflector strut the other end to the sub-reflector lug.

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 4.5M VSAT ANTENNA USER MANUAL

Square steel Bolt M8x25

Spring washer Ø8
Flat washer Ø8

Figure 7

Notes: special spanners can be recommended when installing.

B). Use the bolt M8x25, spring washer Ø8, flat washer Ø8 and nutØ8 connect four sub-reflector
brackets onto the holes which had been prepared on each panel such as Figure 8.

Sub-reflector support

Bolt M8x25
Spring washer Ø8
Flat washer Ø8
Support bracket
Nut Ø8

Figure 8

SECTION Ⅳ KINGPOST ASSEMBLY

● Take out the 360°rotatable kingpost from the iron shelf 7-2.

● Using the crane lift the kingpost smoothly onto the non-penetrating mount as shown below, and
using M24x80 bolt and M24 flat washer connect the kingpost to the non-penetrating mount. During
the whole installation process, please don’t release the lifting ropes. Until the kingpost with mount
have been completely fixed firmly, loosen the lifting ropes.

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 4.5M VSAT ANTENNA USER MANUAL

M24x80

Figure 9

SECTION Ⅴ CONNECTION OF KING POST WITH THE HUB

● These are four holes (Φ18mm) in the bottom of the hub as shown below. Please using the lifting
rope bound with four holes and lift the whole antenna head moving to the top of kingpost to stop.

Lifting hole

Figure 10
Notes: When adjusting the position of main reflector, there should be 45°between four sub-reflector
struts and the horizontal level, and the (Φ80mm) hole should be located at lower part.

There are two support lugs located the left and right top of the king post. These should relate to holes
were designed at bottom of hub by using M16 bolt, spring washer Ø16, flat washer Ø16 and nutM16.
EL support lug must correspond with the hub number marked referring to the following figs.

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 4.5M VSAT ANTENNA USER MANUAL

Figure 11
● Using the 12 pcs M16x60 bolt, Φ16 flat washer, spring washer and M16 nuts fix the hub to the king
post. At first find out the number of El support lug which number must correspond with the number
at the bottom of hub and connect them fixed. And then connect rest of two support lugs.

The number marked

on EL support and
the hub

Cotter pin

Support lugs

Figure 12

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 4.5M VSAT ANTENNA USER MANUAL

El Jack screw
tube support lug

King post support lugs

Gear box

Figure 13
Notice: If customer bought the motorized antenna, please refer to Fig 15 which is a motorized
drive structure.

SECTION Ⅺ LIMIT SWITCH BOX AND RESOLVERS ASSEMBLY

Limit switch boxes installation (Limit switches had been installed)
● Take out of Az/El limit switch boxes from the wooden case 7-2
Note: The bottoms of limit switch boxes are different as following. One of AZ the other is EL.
Select the correct limit switch boxes to install on the Az and El position of antenna.

Big hole should install on AZ Small hole should install on EL

Nut Ø20 and flat

washer Ø20

Screw tube cover

Figure 14

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 4.5M VSAT ANTENNA USER MANUAL
● Take out the fix axis from the limit switch boxes and insert the fix axis into the hole as below.

Red O-ring as right

photo shows two
block pieces will
control two limit
switches respectively.
After install limit
switch system require
to adjust that by four
nuts.

Figure 15

● Take out the resolvers from the limit switch boxes and disassemble resolver to the two half parts:
upper resolver and lower resolver.

Resolver Lower of resolver

Upper of resolver

Figure 16

● Loosen 3pcs of bolts fixed on the limit switch box and use them fix the upper resolver onto the limit
switch box.

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Bolt

Figure 17

Inner of limit switch box (limit switch has

been assembled before leaving the factory

Marks
as
shown

Figure 18
Note: Before install limit switch box on the antenna, you need adjust axis of limit switch.
Because if the axis adjusts too long which will obstruct the fixed axis.
● Loosen the Inner hexagon screw and adjust the position of its axis.

Figure 19

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● Assemble limit switch box on the Fix axis by shaft coupling.

Shaft coupling

Connect with resolver axis Connect with Fix axis

Figure 20

● Place the Az and El limit switch box onto the corresponding mounting position of the antenna, and
then screw two long bolts to connect upper and lower resolver together firmly as following.

Resolver

Az limit switch El limit switch

Figure 21
● Cover Az and El limit switch boxes and using four M3 bolts screw limit switch boxes to the antenna,
after all bolts and nuts connect well to tighten them firmly as shown below.

Az El

Figure 22

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 4.5M VSAT ANTENNA USER MANUAL

SECTION Ⅻ 2 PORTS FEED SYSTEM ASSEMBLY

● Take out of the feed system carefully from the wooden case 7-5. (Feed and OMT had assembled)
● Put the OMT towards up direction and lift the whole feed system into the hole of the hub.

C-band Linear feed system Ku-band Linear feed system

Feed and OMT had assembled

Figure 23

● Using 8 M8x25 bolts, Φ8 flat washers and spring washers screw the flange into the top of the hub
and tighten them firmly.

Ku-band feed system

Figure 24

● After installing the feed system, the bottom of the feed tube as shown as below.

Figure 25

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 4.5M VSAT ANTENNA USER MANUAL

Figure 26 2 port polarization adjustment

Circular polarization: Switch feed from RHCP TO LHCP

Reference with Figure 35, user can switch feed from RHCP to LHCP only by rotating circular polarizer
90deg (moving 2 screw holes and screw on).

Rotate two screw holes and fixed

Figure 27
Switch circular polarization to linear polarization

Circular polarization

Figure 28 2 port circular polarization OMT

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 4.5M VSAT ANTENNA USER MANUAL

Figure 29 Linear Polarization conversion kit

NOTICE:
1. Take off the circular polarization OMT from the feed support tube.
2. Remove the circular polarization away and take place the linear polarization
conversion kit.
3. Then take back feed system into the feed support tube.
Linear Polarization adjustment

While adjusting the polarization, just loose the bolts which connect the OMT rotating joint flange and

feed pipe flange don’t move away the bolts. Slightly and slowly even rotate OMT to the polarized

direction, and then tighten them.

Please loosen the

bolts to adjust
polarization

Figure 30 2 port linear polarization feed

SECTION Ⅻ SUB-REFLECTOR ADJUSTMENT

● Using 4 pcs M12 long bolt, big flat washer and spring washer connect sub-reflector with four
sub-reflector support struts, and then lifting the whole sub-reflector onto the main reflector.

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 4.5M VSAT ANTENNA USER MANUAL

Figure 31
2. Adjusting sub-reflector

Sub-reflector template

Figure 32

Figure 33 unit: mm
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 4.5M VSAT ANTENNA USER MANUAL
After installation, the sub-reflector adjustment template can be used to adjust the height of
sub-reflector.
Adjust requirement: Vertical axis of sub-reflector should be same direction with the vertical axis of
main reflector and the feed horn, and the distance between sub-reflector and surface of feed horn port
can be referred to Fig 33 (C-band) and 34(Ku-band). Please use sub-reflector template to adjust in
according to the follow two ways.

A) Take out of sub-reflector template and install it, and relax the four-claw of the template on feed horn
(be careful not to harm horn film), so as to the distance between sub reflector and three lines marked
on sub reflector installation template are same, then tighten bolts, turn the installation template by 90°
and repeat above procedure to adjust the sub-reflector until the center of sub-reflector and installation
template center lap over.
B). Loosen bolts that connect four- screw and long screw, adjust sub-reflector and make the distance
between sub-reflector and upper interface of installation model is less than 0.5mm. Turn the
installation model by 90°and repeat the above procedure. Tighten the bolts, if the requirement cannot
be reached after all these have been done, please loosen the bolts of the four-screw and support and
knock at the four-screw with a wooden hammer until reach the requirement.

Notes:
①Please wear the soft soled shoes to walk on the main reflector to avoid the reflector panels
deformation.
② Be careful do not to damage the surface coat of the main reflector.

SECTION Ⅸ AERONAUTICAL LAMP INSTALLATION

● Take out of the aeronautical lamp support rod from the wooden case 7-4 and take out of the
aeronautical lamp from the wooden case 7-5.

Aeronautical lamp

Support rod

Figure 34

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 4.5M VSAT ANTENNA USER MANUAL

● At first connect the aeronautical lamp with the threaded end of support rod and screw them fixed.
Then connect other end of support rod to the brace which located at the top of the antenna
reflector as shown below.

Figure 35

SECTION Ⅹ LIGHTNING KIT ASSEMBLY (OPTION)

When the El angle of antenna is not more than 60deg, the lightning rod assembly provided by AST can
be used.
Note:
① Resistance of lightning rod grounding net should be less than 5Ω
② When antenna El is more than 60°, separate lightning rod system is suggested to use.
a Please take out of Lightning Kit Assembly.
b Assemble bracket to reflector back structure.
c Loosen bolts, adjust lightning rod in according to antenna El, and make it vertical with ground, then
tighten the bolts.
d Please fix lead cable to likely position of reflector back structure by using clip, along kingpost
connect lead end with grounding.
Note: If grounding has been connected to antenna mount, lead cable end can be directly
connected to anchor bolts. Please install the lightning rod assembly on the ground in
advance, and then lift the antenna head to the Kingpost as a whole.

SECTION Ⅺ ANTENNA ASSEMBLY PROCESS WITHOUT CRANE

If there is no crane in installation site, false work can be used, installation process as follows:
1) Connect frame first
2) Kingpost

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 4.5M VSAT ANTENNA USER MANUAL
3) Assemble feed to hub
4) Assemble hut to reflector
5) Other process same as the state of using crane
Note: During operation, please pay attention to safety of worker and equipments.

SECTION Ⅻ ANTENNA SYSTEM OPERATION AND MAINTENANCE

Antenna system use

After finish antenna system installation, the antenna system should be in safety state ( collection state,

El=90 °)

a. Antenna system pointing to satellite

After mark sure antenna Az and El, use compass to aim at El, loosen Az adjuster, turning antenna Az

and make it point to satellite, then fit on Az adjuster, adjust Az or EL in according to receiving signal.

Note: please make sure the center of antenna beam pointing to satellite and not Side lobe.

When using, please pay attention to the following:

a. When wind speed is over 216km/h, the antenna must be clocked and do not work.

b. All operators can work after being trained.

The antenna system should be turned off at once, if unusual voice and condition is appeared, the
antenna system cannot work until remove trouble.
In the condition of normal working, the earth station antenna should be repaired periodically; the work

life of antenna is 10 years at least. The maintenance mainly includes the following works:

1) Antenna equipment maintenance

2) Lubricating antenna rotation and bearing

After working some times, antenna entire inspection should be carried out, adjust Az/El travel warping,

detailed operation process as following:

A) Mechanical parts maintenance

It is suggested that a periodic inspection for antenna use and surface coat be performed at least six

months.

1) Inspect whether there is any water vapor in lead screw cover, if yea, please take out of cover, make

the lead screw dry and clear

2) Inspect whether lead screw cover appears disrepair and aging because being uncovered long

time, if yea, it should be repaired or replaced in time.

3) Inspect whether there is any interface dandification in bearing because long time rub reciprocally, if
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 4.5M VSAT ANTENNA USER MANUAL
yea, please change copper cover of interface, and lube.

4) When antenna running, inspect whether the voice from bearing and driver is normal, if there is any

exceptional voice, it should show there are some troubles, user should turn off antenna and inspect

whether installation positions of antenna parts appear excursion or parts lubricated have not lube.

5) Inspect whether surface coat of antenna every parts appears disrepair, if disrepair is serious, user

should spray coat again.

6) Every bearing, connector and others steel parts may be changed with over much rust, hole and

any parts structure failure.

7) Check all bolting locations, all bolts should be tight

B) Lubricating lead screw

Before lubricating, please turn off servo system, lubrication process as follow:

1) Open lead screw cover

2) Manual rotate lead screw, and clear dirt

3) Lubricate in according to request shown as lubrication table

4) After finish lubricating , adjust lead screw location and make it connect to antenna equipment in

good, fix on lead screw and lubricate on port of lead screw cover for avoiding。

5) Lubricating antenna hardware

Except lead screw, every hardware lubricating should be prompt, when antenna working,

Lubrication table

Components to be Type of lube Lube quantity Frequency

lubricated (months)
Rotation joint L-CLC80W/90 (ZBE34006-87) Right 2

Gear box L-CLC80W/90 (ZBE34006-87) 500ml / pc 12

Lead screw No. 2 current (GB7324-87) Right 3

C) Surface coat maintenance

In the condition of no serous damaged on surface coat, it is suggested that a periodic surface

managing be performed at least one year

D) Antenna surface coat table

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 4.5M VSAT ANTENNA USER MANUAL
Components Surface coat Coat color

Reflector Baking finish White

Lead screw Hot dipped Zinc

Other steel parts 1. Spraying sand pretreatment Silver

2. Spray zinc

3. Spray undercoat

4. Spray surface coat

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